US9482015B2 - Panel forming - Google Patents
Panel forming Download PDFInfo
- Publication number
- US9482015B2 US9482015B2 US15/085,535 US201615085535A US9482015B2 US 9482015 B2 US9482015 B2 US 9482015B2 US 201615085535 A US201615085535 A US 201615085535A US 9482015 B2 US9482015 B2 US 9482015B2
- Authority
- US
- United States
- Prior art keywords
- core
- board
- floor panels
- forming
- floor
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Active
Links
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- 229920002522 Wood fibre Polymers 0.000 claims abstract description 31
- 229920001187 thermosetting polymer Polymers 0.000 claims abstract description 27
- 239000002025 wood fiber Substances 0.000 claims abstract description 10
- 238000000034 method Methods 0.000 claims description 52
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- 239000011162 core material Substances 0.000 description 140
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Images
Classifications
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F15/00—Flooring
- E04F15/02—Flooring or floor layers composed of a number of similar elements
- E04F15/02038—Flooring or floor layers composed of a number of similar elements characterised by tongue and groove connections between neighbouring flooring elements
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
- B27F—DOVETAILED WORK; TENONS; SLOTTING MACHINES FOR WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES
- B27F1/00—Dovetailed work; Tenons; Making tongues or grooves; Groove- and- tongue jointed work; Finger- joints
- B27F1/02—Making tongues or grooves, of indefinite length
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
- B27N—MANUFACTURE BY DRY PROCESSES OF ARTICLES, WITH OR WITHOUT ORGANIC BINDING AGENTS, MADE FROM PARTICLES OR FIBRES CONSISTING OF WOOD OR OTHER LIGNOCELLULOSIC OR LIKE ORGANIC MATERIAL
- B27N3/00—Manufacture of substantially flat articles, e.g. boards, from particles or fibres
- B27N3/04—Manufacture of substantially flat articles, e.g. boards, from particles or fibres from fibres
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B21/00—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board
- B32B21/02—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board the layer being formed of fibres, chips, or particles, e.g. MDF, HDF, OSB, chipboard, particle board, hardboard
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form
- B32B3/02—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by features of form at particular places, e.g. in edge regions
- B32B3/06—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by features of form at particular places, e.g. in edge regions for securing layers together; for attaching the product to another member, e.g. to a support, or to another product, e.g. groove/tongue, interlocking
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
- E04C2/10—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products
- E04C2/24—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products laminated and composed of materials covered by two or more of groups E04C2/12, E04C2/16, E04C2/20
- E04C2/246—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products laminated and composed of materials covered by two or more of groups E04C2/12, E04C2/16, E04C2/20 combinations of materials fully covered by E04C2/16 and E04C2/20
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F15/00—Flooring
- E04F15/02—Flooring or floor layers composed of a number of similar elements
- E04F15/02161—Floor elements with grooved main surface
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F15/00—Flooring
- E04F15/02—Flooring or floor layers composed of a number of similar elements
- E04F15/04—Flooring or floor layers composed of a number of similar elements only of wood or with a top layer of wood, e.g. with wooden or metal connecting members
- E04F15/041—Flooring or floor layers composed of a number of similar elements only of wood or with a top layer of wood, e.g. with wooden or metal connecting members with a top layer of wood in combination with a lower layer of other material
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F15/00—Flooring
- E04F15/02—Flooring or floor layers composed of a number of similar elements
- E04F15/10—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials
- E04F15/102—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials of fibrous or chipped materials, e.g. bonded with synthetic resins
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F15/00—Flooring
- E04F15/02—Flooring or floor layers composed of a number of similar elements
- E04F15/10—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials
- E04F15/107—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials composed of several layers, e.g. sandwich panels
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
- B27F—DOVETAILED WORK; TENONS; SLOTTING MACHINES FOR WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES
- B27F1/00—Dovetailed work; Tenons; Making tongues or grooves; Groove- and- tongue jointed work; Finger- joints
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
- B27F—DOVETAILED WORK; TENONS; SLOTTING MACHINES FOR WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES
- B27F1/00—Dovetailed work; Tenons; Making tongues or grooves; Groove- and- tongue jointed work; Finger- joints
- B27F1/02—Making tongues or grooves, of indefinite length
- B27F1/04—Making tongues or grooves, of indefinite length along only one edge of a board
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
- B29B13/00—Conditioning or physical treatment of the material to be shaped
- B29B13/02—Conditioning or physical treatment of the material to be shaped by heating
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2471/00—Floor coverings
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2607/00—Walls, panels
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
- B41J—TYPEWRITERS; SELECTIVE PRINTING MECHANISMS, i.e. MECHANISMS PRINTING OTHERWISE THAN FROM A FORME; CORRECTION OF TYPOGRAPHICAL ERRORS
- B41J2/00—Typewriters or selective printing mechanisms characterised by the printing or marking process for which they are designed
- B41J2/005—Typewriters or selective printing mechanisms characterised by the printing or marking process for which they are designed characterised by bringing liquid or particles selectively into contact with a printing material
- B41J2/01—Ink jet
- B41J2/015—Ink jet characterised by the jet generation process
- B41J2/02—Ink jet characterised by the jet generation process generating a continuous ink jet
- B41J2/03—Ink jet characterised by the jet generation process generating a continuous ink jet by pressure
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F2201/00—Joining sheets or plates or panels
- E04F2201/01—Joining sheets, plates or panels with edges in abutting relationship
- E04F2201/0153—Joining sheets, plates or panels with edges in abutting relationship by rotating the sheets, plates or panels around an axis which is parallel to the abutting edges, possibly combined with a sliding movement
- E04F2201/0161—Joining sheets, plates or panels with edges in abutting relationship by rotating the sheets, plates or panels around an axis which is parallel to the abutting edges, possibly combined with a sliding movement with snap action of the edge connectors
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F2201/00—Joining sheets or plates or panels
- E04F2201/02—Non-undercut connections, e.g. tongue and groove connections
- E04F2201/023—Non-undercut connections, e.g. tongue and groove connections with a continuous tongue or groove
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F2203/00—Specially structured or shaped covering, lining or flooring elements not otherwise provided for
- E04F2203/04—Specially structured or shaped covering, lining or flooring elements not otherwise provided for comprising a plurality of internal elongated cavities arranged in substantially parallel rows
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F2203/00—Specially structured or shaped covering, lining or flooring elements not otherwise provided for
- E04F2203/08—Specially structured or shaped covering, lining or flooring elements not otherwise provided for with a plurality of grooves or slits in the back side, to increase the flexibility or bendability of the elements
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24777—Edge feature
Abstract
Description
-
- creating wood fibre chips by forming core grooves in the rear side of previously produced panel;
- producing a mix by mixing the wood chips with thermosetting resin,
- scattering the mix of wood chips and thermosetting resin on the upper and/or lower side of the core,
- forming a board by curing the mix with heat and pressure,
- cutting the board into several floor panels, and
- forming a locking system at a first and a second panel edge, the locking system comprises a strip, a locking element and a locking grove for horizontal locking and a tongue and a tongue groove for vertical locking.
-
- forming a large board with convex pretension backwards by connecting the core, the surface layer and the backing layer with heat and pressure;
- dividing the board into several floor panels;
- forming core grooves at the rear side of the panels such that the convex pretension is at least partly released.
2. The building panels as in
3. The building panels as in
4. The building panels as in any one of the embodiments 1-3, wherein the entire parts of at least one core groove (19) is arranged inside the vertical plane VP at all edges.
5. The building panels as in any one of the preceding embodiments, wherein the building panels are rectangular with long edges (1 a, 1 b) and short edges (1 c, 1 d) and wherein the core grooves (19) are essentially parallel with the long edges.
6. The building panels as in any one of the preceding embodiments, wherein the core groove depth (GD) is at least 0.3 times the floor thickness (T).
7. The building panels as in any one of the preceding embodiments, wherein the core grooves (19) comprises an opening with a groove width (GW) that is larger than an inner part of said groove.
8. The building panels as in any one of the preceding embodiments, wherein the backing layer (4) comprises essentially the same types of fibres as the core (3).
9. A method to produce floor panels, each having a surface layer (2) on a front side, a backing layer (4) on a rear side and an intermediate core (3), wherein the core and the surface and backing layer all comprise wood fibres and thermosetting resins and wherein the method comprises the steps of:
-
- creating wood fibre chips (21) by forming core grooves (19) in a rear side of previously produced panel;
- producing a mix by mixing the wood fibre chips with a thermosetting resin;
- scattering the mix on the upper and/or lower side of a core;
- forming the core and the mix to a board by curing the mix with heat and pressure;
- cutting the board into several floor panels; and
- forming a locking system at a first and a second edge of the floor panels, the locking system comprises a locking groove (14) and a strip (6) with a locking element (8) for horizontal locking and a tongue (10) and a tongue groove (9) for vertical locking.
10. The method as inembodiment 9 wherein the mix is scattered on the lower side of the core.
11. The method as inembodiment
12. The method as in any one of the embodiments 9-11, wherein the core is HDF.
13. The method as in any one of the embodiments 9-12, wherein the core grooves are formed prior to the forming of the locking system at long or short edges of the floor panels.
14. The method as in any one of the embodiments 9-13, wherein the core grooves are formed by a jumping tool comprising several rotating saw blades or a carving tool.
15. The method as in any one of the embodiments 9-14, wherein the pressed board is more convex than the floor panels.
16. A wood based floor panel having an upper (2) and a lower (4) layer of solid wood, wherein the lower layer comprises cavities (26) and that the upper layer (2) forms an upper part (27) of the cavities (26).
17. The floor panel as in embodiment 16, wherein one pair of opposite panel edges comprises a mechanical locking system (9,10,6,8,14) for locking the floor panel to an adjacent essentially identical floor panel vertically and horizontally.
18. A method to produce essentially flat floor panels, each having a surface layer (2) on a front side, a backing layer (4) on a rear side and an intermediate core (3), wherein the surface and backing layer comprise thermosetting resins and wherein the method comprises the steps of: - forming a large board with convex pretension backwards by connecting the core, the surface layer and the backing layer with heat and pressure
- dividing the board into several floor panels;
- forming core grooves (19) at the rear side of the panels such that the convex pretension is at least partly released.
19. The method as in embodiment 18, wherein the core grooves are formed after the dividing of the board into several floor panels.
20. The method as inembodiments 18 or 19, wherein the core grooves are formed after the dividing of the board into several floor panels.
Claims (20)
Priority Applications (7)
Application Number | Priority Date | Filing Date | Title |
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US15/085,535 US9482015B2 (en) | 2012-07-02 | 2016-03-30 | Panel forming |
US15/164,523 US9556623B2 (en) | 2012-07-02 | 2016-05-25 | Panel forming |
US15/398,484 US9840849B2 (en) | 2012-07-02 | 2017-01-04 | Panel forming |
US15/809,582 US10619356B2 (en) | 2012-07-02 | 2017-11-10 | Panel forming |
US16/814,074 US11002022B2 (en) | 2012-07-02 | 2020-03-10 | Panel forming |
US17/228,240 US11781323B2 (en) | 2012-07-02 | 2021-04-12 | Panel forming |
US18/240,192 US20240093507A1 (en) | 2012-07-02 | 2023-08-30 | Panel forming |
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US201261667190P | 2012-07-02 | 2012-07-02 | |
US13/932,406 US9140010B2 (en) | 2012-07-02 | 2013-07-01 | Panel forming |
US14/825,719 US9663956B2 (en) | 2012-07-02 | 2015-08-13 | Panel forming |
US15/085,535 US9482015B2 (en) | 2012-07-02 | 2016-03-30 | Panel forming |
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US17/228,240 Active 2033-07-25 US11781323B2 (en) | 2012-07-02 | 2021-04-12 | Panel forming |
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Cited By (7)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US9840849B2 (en) | 2012-07-02 | 2017-12-12 | Ceraloc Innovation Ab | Panel forming |
US9975267B2 (en) | 2013-08-27 | 2018-05-22 | Valinge Innovation Ab | Method for producing a lamella core |
US10066400B2 (en) | 2011-08-29 | 2018-09-04 | Ceraloc Innovation Ab | Mechanical locking system for floor panels |
WO2021018918A1 (en) * | 2019-07-29 | 2021-02-04 | I4F Licensing Nv | Decorative panel and method of producing such a panel |
US11377855B2 (en) * | 2019-03-25 | 2022-07-05 | Ceraloc Innovation Ab | Mineral-based panel comprising grooves and a method for forming grooves |
US11712816B2 (en) | 2019-03-05 | 2023-08-01 | Ceraloc Innovation Ab | Method and system for forming grooves in a board element and an associated panel |
US11725398B2 (en) | 2019-12-27 | 2023-08-15 | Ceraloc Innovation Ab | Thermoplastic-based building panel comprising a balancing layer |
Families Citing this family (27)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
SE525657C2 (en) | 2002-04-08 | 2005-03-29 | Vaelinge Innovation Ab | Flooring boards for floating floors made of at least two different layers of material and semi-finished products for the manufacture of floorboards |
BE1017157A3 (en) | 2006-06-02 | 2008-03-04 | Flooring Ind Ltd | FLOOR COVERING, FLOOR ELEMENT AND METHOD FOR MANUFACTURING FLOOR ELEMENTS. |
US8935899B2 (en) | 2012-02-02 | 2015-01-20 | Valinge Innovation Ab | Lamella core and a method for producing it |
US8875464B2 (en) | 2012-04-26 | 2014-11-04 | Valinge Innovation Ab | Building panels of solid wood |
US10035358B2 (en) | 2012-07-17 | 2018-07-31 | Ceraloc Innovation Ab | Panels with digital embossed in register surface |
US9446602B2 (en) * | 2012-07-26 | 2016-09-20 | Ceraloc Innovation Ab | Digital binder printing |
GB2538492A (en) | 2015-05-11 | 2016-11-23 | Cook Medical Technologies Llc | Aneurysm treatment assembly |
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US9140010B2 (en) | 2015-09-22 |
US20160265236A1 (en) | 2016-09-15 |
US9840849B2 (en) | 2017-12-12 |
US20180080232A1 (en) | 2018-03-22 |
US20140000197A1 (en) | 2014-01-02 |
US9556623B2 (en) | 2017-01-31 |
US20170114550A1 (en) | 2017-04-27 |
US20160208501A1 (en) | 2016-07-21 |
US9663956B2 (en) | 2017-05-30 |
US11002022B2 (en) | 2021-05-11 |
US10619356B2 (en) | 2020-04-14 |
US11781323B2 (en) | 2023-10-10 |
US20170114549A9 (en) | 2017-04-27 |
US20210363760A1 (en) | 2021-11-25 |
US20150345153A1 (en) | 2015-12-03 |
US20200208411A1 (en) | 2020-07-02 |
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